Golf club face plates with internal cell lattices and related methods

ABSTRACT

Embodiments of golf club face plates with internal cell lattices are presented herein. Other examples and related methods are also disclosed herein.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation of U.S. patent application Ser. No. 16/989,747,filed Aug. 10, 2020, which is a continuation of U.S. patent applicationSer. No. 16/405,904, filed May 7, 2019, now U.S. Pat. No. 10,737,147issued Aug. 11, 2020, which is a continuation of U.S. patent applicationSer. No. 15/859,912, filed Jan. 2, 2018, now U.S. Pat. No. 10,322,320issued Jun. 18, 2019, which is a divisional of U.S. patent applicationSer. No. 15/162,482, filed on May 23, 2016, now U.S. Pat. No. 9,889,347,issued Feb. 13, 2018, which claims the benefit of U.S. ProvisionalPatent Application No. 62/293,914, filed on Feb. 11, 2016, and U.S.Provisional Patent Application No. 62/165,683, filed on May 22, 2015,and is a continuation-in-part of U.S. patent application Ser. No.14/157,345, filed on Jan. 16, 2014, now U.S. Pat. No. 9,409,065, whichis a continuation of U.S. patent application Ser. No. 13/352,086, filedon Jan. 17, 2012, now U.S. Pat. No. 8,663,027, which claims the benefitof U.S. Provisional Patent Application No. 61/537,278, filed on Sep. 21,2011, the contents of all which are incorporated fully herein byreference.

TECHNICAL FIELD

The present disclosure relates generally to sports equipment, andrelates, more particularly, to golf club face plates with internal celllattices and related methods.

BACKGROUND

The development of golf club head technology has been characterized inpart by the desire to enhance playability characteristics while managingweight and mass location considerations. The ability to alter orredistribute mass at or around locations of high stress and/or oflimited thickness in a golf club head, however, has to be balanced withrespect to structural resilience considerations. Considering the above,further developments in terms of weight redistribution will advance theplayability characteristics of golf club heads.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will be better understood from a reading of thefollowing detailed description of examples of embodiments, taken inconjunction with the accompanying figures in the drawings.

FIG. 1 illustrates a front perspective view of a golf club headcomprising a face plate coupled to a club head body.

FIG. 2 illustrates a cross-sectional view of the face plate of FIG. 1,cut along line II-II.

FIG. 3 illustrates a perspective view of portions of different layerscomprising the face plate of FIG. 1 prior to being merged together.

FIG. 4 illustrates a front view of a midsection layer of the face plateof FIG. 1, comprising a lattice pattern and alignment elements.

FIG. 5 illustrates a finite element analysis graphic showing unevenstress distribution detrimentally concentrated in and around voidportions of an exposed cell lattice in an embodiment of a face platelacking an inner skin layer.

FIG. 6 illustrates a perspective view of a portion of the cell latticeof the face plate of FIG. 1.

FIG. 7 illustrates a front view of a portion of a cell lattice of a faceplate.

FIG. 8 illustrates a side view of a portion of a cell lattice of a faceplate.

FIG. 9 illustrates a side view of a portion of a cell lattice of a faceplate.

FIG. 10 illustrates a flowchart for a method for providing a face platefor a golf club head.

FIG. 11 illustrates a portion of a cell lattice of a face plate.

FIG. 12 illustrates a portion of a cell lattice of a face plate.

FIG. 13 illustrates a portion of a cell lattice of a face plate.

FIG. 14 illustrates a portion of a cell lattice of a face plate.

FIG. 15 illustrates a portion of a cell lattice of a face plate.

FIG. 16 illustrates a portion of a cell lattice of a face plate.

FIG. 17 illustrates a cross-sectional view of a face plate having a celllattice with cells that vary in height amongst each other.

FIG. 18 presents a front “x-ray” perspective view of a faceplatecomprising a cell lattice variable cell dimensions.

FIG. 19 illustrates a front view of a faceplate subdivided intodifferent cell lattice regions with one or more cell latticestherewithin.

FIG. 20 illustrates a front view of a faceplate subdivided intodifferent cell lattice regions with one or more cell latticestherewithin.

FIG. 21 illustrates a front view of a faceplate subdivided intodifferent cell lattice regions with one or more cell latticestherewithin.

FIG. 22 illustrates a front view of a faceplate subdivided intodifferent cell lattice regions with one or more cell latticestherewithin.

FIG. 23 illustrates a flow chart for a method of manufacturing a faceplate for a golf club head.

FIG. 24 illustrates a front perspective view of a golf club headcomprising a face plate coupled to a club head body.

FIG. 25 illustrates a front view of a face plate of a golf club headhaving a cell lattice according to an embodiment.

FIG. 26 illustrates a front view of a face plate of a golf club headhaving a cell lattice according to another embodiment.

FIG. 27 illustrates a side view of a portion of a cell lattice of a faceplate.

FIG. 28A illustrates a front cross sectional view of a portion of a faceplate having a cell lattice according to one embodiment.

FIG. 28B illustrates a front cross sectional view of a portion of a faceplate having a cell lattice according to one embodiment.

FIG. 28C illustrates a front cross sectional view of a portion of a faceplate having a cell lattice according to one embodiment.

For simplicity and clarity of illustration, the drawing figuresillustrate the general manner of construction, and descriptions anddetails of well-known features and techniques may be omitted to avoidunnecessarily obscuring the present disclosure. Additionally, elementsin the drawing figures are not necessarily drawn to scale. For example,the dimensions of some of the elements in the figures may be exaggeratedrelative to other elements to help improve understanding of embodimentsof the present disclosure. The same reference numerals in differentfigures denote the same elements.

The terms “first,” “second,” “third,” “fourth,” and the like in thedescription and in the claims, if any, are used for distinguishingbetween similar elements and not necessarily for describing a particularsequential or chronological order. It is to be understood that the termsso used are interchangeable under appropriate circumstances such thatthe embodiments described herein are, for example, capable of operationin sequences other than those illustrated or otherwise described herein.Furthermore, the terms “include,” and “have,” and any variationsthereof, are intended to cover a non-exclusive inclusion, such that aprocess, method, system, article, device, or apparatus that comprises alist of elements is not necessarily limited to those elements, but mayinclude other elements not expressly listed or inherent to such process,method, system, article, device, or apparatus.

The terms “left,” “right,” “front,” “back,” “top,” “bottom,” “over,”“under,” and the like in the description and in the claims, if any, areused for descriptive purposes and not necessarily for describingpermanent relative positions. It is to be understood that the terms soused are interchangeable under appropriate circumstances such that theembodiments of the apparatus, methods, and/or articles of manufacturedescribed herein are, for example, capable of operation in otherorientations than those illustrated or otherwise described herein.

DETAILED DESCRIPTION

In one embodiment, a method for providing a face plate for a golf clubhead can comprise providing an inner skin of the face plate, providingan outer skin of the face plate, providing a midsection of the faceplate, and bounding the midsection between the inner skin and the outerskin. Providing the midsection can comprise providing a plurality ofmidsection layers comprising a first midsection layer and a secondmidsection layer, forming a first lattice pattern through the firstmidsection layer, and forming a second lattice pattern through thesecond midsection layer. Providing the inner skin, the outer skin, andthe midsection can comprise providing each of the midsection, the innerskin, or the outer skin as separate distinct pieces. Bounding themidsection can comprise diffusion bonding the inner skin, themidsection, and the outer skin together, including the first and secondmidsection layers, into a single integral piece of material that issubstantially seamless between the inner skin and the midsection andbetween the midsection and the outer skin. After the diffusion bonding,a midsection central area of the midsection can comprise a cell lattice,the cell lattice can comprise a plurality of walls defining a pluralityof cells in a hexagonal pattern, the plurality of walls and theplurality of cells of the cell lattice can be defined at least in partby the first and second lattice patterns, the cell lattice can be fullybounded between the inner and outer skins of the face plate, and amidsection perimeter area of the midsection can bound the midsectioncentral area and can be devoid of the cell lattice. Forming the firstlattice pattern through the first midsection layer can comprise forminga first cutout through the first midsection layer, the first cutoutconfigured to define a first volume portion of a first cell of the celllattice. Forming the second lattice pattern through the secondmidsection layer can comprise forming a second cutout through the secondmidsection layer, the second cutout configured to define a second volumeportion of the first cell. Bounding the midsection can comprise aligningthe second midsection layer over the first midsection layer such thatthe first and second cutouts are centered about a first cell axis of thefirst cell.

In one embodiment, a method for providing a face plate for a golf clubhead can comprise providing an inner skin of the face plate, providingan outer skin of the face plate, providing a midsection of the faceplate, and coupling the midsection between the inner skin and the outerskin such that an inner midsection end of the midsection is coupled tothe inner skin of the face plate, and such that an outer midsection endof the midsection is coupled to the outer skin of the face plate.Providing the midsection can comprise providing a cell lattice in themidsection, the cell lattice comprising a plurality of walls defining aplurality of cells.

In one embodiment, a face plate for a golf club head can comprise aninner skin, an outer skin, and a midsection. The midsection can comprisean inner midsection end coupled to the inner skin, an outer midsectionend coupled to the outer skin, and a cell lattice comprising a pluralityof walls defining a plurality of cells between the inner midsection endand the outer midsection end.

Other examples and embodiments are further disclosed herein. Suchexamples and embodiments may be found in the figures, in the claims,and/or in the present description.

Turning to the drawings, FIG. 1 illustrates a front perspective view ofgolf club head 10 comprising face plate 100 coupled to club head body109. FIG. 2 illustrates a cross-sectional view of face plate 100 cutalong line II-II of FIG. 1. As can be seen in FIG. 2, face plate 100comprises inner skin 210, outer skin 120, and midsection 230 betweeninner skin 210 and outer skin 120, where midsection 230 comprises celllattice 240 having walls 241 defining cells 242. In the present example,cell lattice 240 extends from inner midsection end 245 (where celllattice 240 is coupled to inner skin 210), to outer midsection end 246(where cell lattice 240 is coupled to inner skin 210). Cell lattice 240is thus fully encapsulated within faceplate 100 in the present example,between inner skin 120 and outer skin 210, and by perimeter midsectionarea 232. Although inner midsection end 245 and outer midsection end 246are represented along dotted lines in FIG. 2, in the present embodimentthe interface between midsection 230 and inner skin 210 or outer skin120 may be seamless or imperceptible visually and/or structurally.

The different portions of faceplate 100 can comprise differentthicknesses. In the present example, the thickness of outer skin 120 isapproximately 0.03 inches (approximately 0.08 millimeters (mm); thethickness of midsection 230 is approximately 0.07 inches (approximately1.78 mm); and the thickness of inner skin varies, being approximately0.05 inches (approximately 0.13 mm) towards the center, andapproximately 0.03 inches (approximately 0.08 mm) towards the perimeter.The thickness of inner skin 210 is greater than the thickness of outerskin 120 in the present example, where inner skin 210 faces away fromthe impact surface of faceplate 100, to better distribute impactstresses throughout the faceplate. In some examples, the thickness ofinner skin 210 and outer skin 120 can be substantially similar to eachother, and/or may not vary.

In the present example, face plate 100 is shown with inner skin 210,outer skin 120, and midsection 230 merged together into a singleintegral piece of material. In some examples, inner skin 210, outer skin120, and/or midsection 230 may be merged together without usingadhesives or fasteners, such as via a high-pressure and/or high-heatprocess. In the same or other examples, such process may comprise adiffusion bonding process. The ability to combine midsection 230 betweeninner skin 210 and outer skin 120 and into a single integral piece ofmaterial can provide many benefits, such as a reduction in the weight offace plate 100 via cell lattice 240. In some examples, encapsulatingcell lattice 240 within face plate 100 can permit weight savings ofapproximately 8% to approximately 25%. Such results can be achievedwithout compromising the strength or durability of face plate 100, andwithout introducing detrimental bending, elastic and/or flexingsusceptibilities that would result from uneven stress distribution if,for example, face plate 100 were made with cell lattice 240 exposedand/or without one of inner skin 210 or outer skin 120. As an example,and skipping ahead in the figures, FIG. 5 illustrates a cross-sectionalview of a finite element analysis graphic showing uneven stressdistribution detrimentally concentrated, as denoted by theheavily-dotted center region, in and around the void portions of anexposed cell lattice in an embodiment comprising only a single skincoupled to the cell lattice.

Backtracking to FIG. 3, a perspective view is illustrated of portions ofdifferent layers 300 comprising face plate 100 prior to being mergedtogether, including midsection layers 330. In the present example,midsection 230 comprises midsection layers 330 merged together into thesingle integral piece of material of face plate 100. In the same orother examples, the plurality of midsection layers 330 can be mergedtogether via the high-pressure and high-heat process described above. Ascan be seen in FIG. 3, inner skin 210 and outer skin 120 can also beformed out of several layers, such as outer skin layers 320 and innerskin layers 310, which may be merged together into the single integralpiece of material of face plate 100. Although in the present embodimentinner skin 210 comprises more inner skin layers 310 than outer skin 120comprises outer skin layers 320, there can be other embodiments wheresuch relationship is inverse, or where both skins comprise the samenumber of layers. There may be other embodiments, however, where one ormore of inner skin 210, outer skin 120, and/or midsection 230 mayoriginally comprise a single layer, rather than a plurality of layerscoupled together.

FIG. 3 shows portions of layers 300 as sheets of metallic material, andillustrate midsection layers 330 with representative cutouts configuredto form cell lattice 240 when merged together. FIG. 4 illustrates afront view of midsection layer 331 of midsection 230, comprising latticepattern 341 and alignment elements 351-354. Lattice pattern 341comprises a plurality of cutouts, such as cutout 342, that define alayer portion of walls 241 and a layer portion of the volume of cells242 of cell lattice 240. In some examples, cell lattice 240 may beformed by one or more processes, such as by machining and/or bychemically etching the cutouts of the different lattice patterns ofmidsection layers 330 prior to merging layers 300 (FIG. 3) together. Inexamples involving the machining of cell lattice 240 or one or more ofits elements, such machining can be carried out via one or moretechniques, such as through computer numerical control (CNC) machining,waterjet cutting, and/or electrical discharge machining.

Although in the present example the cutouts of lattice pattern 341 areall similar to each other, there can be other examples where the cutoutscan have different geometries, different dimensions, such as differentradiuses, different perimeter lengths, different areas, and/or differentvolumes. The same or other examples may comprise other patterns, such asa pattern where a density in the number of cells 242 decreases towardstarget strike region 150 of face plate 100, and/or a pattern where asize or dimension of cells 242 decreases towards target strike region150 of face plate 100.

Referring to FIG. 4, alignment elements 351-354 of midsection layer 331is representative of corresponding alignment elements in other ones oflayers 300 (FIG. 3). Alignment elements 351-354 are configured so thatrespective alignment elements 351-354 of different ones of layers 300will align with each other only in a single orientation when layers 300are stacked as shown in FIG. 3. Thus, when alignment elements 351-354are aligned with each other throughout layers 300, walls 241 and thedifferent lattice patterns of midsection layers 330, such as latticepattern 341, will also be aligned to yield cell lattice 240 (FIGS. 2-3)once layers 300 are merged together. In the present example, by aligningalignment elements 351-354 throughout layers 300, the cutouts of thedifferent layers 300 will also be aligned relative to each other. Forinstance, as can be seen in FIG. 3, cutouts 342 and 343 are located indifferent ones of midsection layers 330, but are both centered aboutcell axis 350 when alignment elements 351-154 are aligned throughoutlayers 300. Once layers 300 are merged together, the different cutoutsof midsection layers 330 that are centered about cell axis 350 define asingle cell of cells 242 of cell lattice 240. There can be otherexamples, however, where cutouts of different ones of midsection layers330 may be offset from each other, rather than aligned or centered abouta cell axis.

In the present example, each of layers 300 of face plate 100 comprisesthe same type of material. As an example, midsection 230, inner skin210, and outer skin 120, and respective midsection layers 330, innerskin layers 310, and outer skin layers 320, comprise a metallic materialsuch as a metallic alloy. In the present example, individual ones oflayers 300, such as layer 331, can comprise a thickness of approximately0.01 inch or approximately 0.25 mm. In the same or other embodiments,one or more of such layers 300 can comprise a thickness ranging frombetween approximately 0.25 mm to approximately 2.54 mm.

In the present embodiment, the metallic material for layers 300 of faceplate 100 can comprise a titanium alloy comprising at leastapproximately 8% aluminum (by volume). In the same or other examples,the metallic alloy can comprise a titanium alloy such as Ti-9S whichcontains 8% Al, 1% V, and 0.2% Si, with the remaining alloy compositionbeing titanium and possibly some trace elements. In some embodiments,Ti-9S contains 6.5%-8.5% Al, between 1%-2% V, a maximum of 0.08% C, amaximum of 0.2% Si, a maximum of 0.3% Fe, a maximum of 0.2% O, a maximumof 0.05% N, trace amounts of Mo, and trace amounts of Sn, with theremaining alloy composition being titanium. In the same or otherexamples, the metallic alloy can comprise a titanium 8-1-1 alloy havingapproximately 8% aluminum, 1% vanadium and 1% chromium. Other materialsmay be used depending on their strength, considering theirbrittleness/elasticity as a beta-type crystal structure. For example, atitanium 6-4 alloy having approximately 6% aluminum and 4% vanadium, maybe used in some embodiments, but can be from 5% to 12% less elastic thantitanium 8-1-1 and may thus require further reinforcement or thicknessfor face plate 100 to properly withstand golf impact stresses. Incontrast, other materials such as commercially pure titanium, may not besuitable to properly withstand the stresses to which face plate 100 issubjected.

There can be examples where the metallic alloy of layers 300 maycomprise an alpha-type crystal structure prior to being merged together,and a stronger beta-type crystal structure after being merged together,such as via the high-heat and high pressure process described above. Asan example, the alpha-type crystal structure may comprise a hexagonalcrystal phase, and/or the beta-type crystal structure may comprise abody-centered cubic crystal phase. The transformation to beta-typecrystal structure can permit the crystal structure of adjacent layers oflayers 300 to be intermeshed together at a molecular level once themerging process is completed to yield the single integral piece ofmaterial for face plate 100.

As can be seen in FIGS. 3-4, the sheets of metallic material containinglayers 300 are larger than face plate 100 in the present example. In thesame or other examples, face plate 100 can be separated from the otherportions of the sheets of metallic material once layers 300 have beenmerged into the single integral piece of material, by water-jetting orby otherwise cutting along a cut perimeter defining face plate edge 101of face plate 100, such as the cut perimeter depicted in dotted lines inFIG. 4.

In the present example, face plate 100 comprises cell lattice 240 in acentral area of midsection 230, as can be seen from the exemplarymidsection layer 331 shown in FIG. 4. Midsection 230 also comprisesperimeter midsection area 232 bounding cell lattice 240 and devoid ofcells 242. Cell lattice 240 is thus separated from face plate edge 101by perimeter midsection area 232. In some examples, separating celllattice 240 from face plate edge 101 can permit cell lattice 240 to bedistanced away from an interface or weld zone with club head body 109when face plate 100 is coupled to a front end of golf club head 10. Inthe same or other examples, such distancing of cell lattice 240 fromface plate edge 101 and the interface with club head body 109 can bebeneficial for permitting a better weld or bond between face plate 100and club head body 109. There can be other examples, however, where celllattice 240 may extend within midsection 230 to face plate edge 101 oradjacent thereto.

Cell lattice 240 comprises a hexagonal isogrid pattern with six subcellsper hexagon in the present example, as can be seen in FIG. 4, providingthe strength-to-weight performance and versatility of a reinforcedhoneycomb structure. In the present embodiment, each of the six subcellscomprise the same triangular shape. In the same or other examples, thedepth of the walls of a cell or subcell (between inner skin 210 andouter skin 120) can be approximately 0.07 inches (approximately 1.78mm), the length of the walls of the cell or subcell can be approximately0.06 inches (approximately 1.53 mm), and/or the thickness of the wallsof the cell or subcell can be approximately 0.01 inches (approximately0.25 mm). In the same or other examples, the depth of the walls of acell or subcell can be approximately 1.27 mm to approximately 3.05 mm,the length of the walls of the cell or subcell can be approximately 1 mmto approximately 3.05 mm, and/or the thickness of the walls of the cellor subcell can be approximately 0.20 mm to approximately 0.76 mm. Otherexamples of cell lattices, however, may comprise different shapes and/ordimensions.

Continuing with the figures, FIG. 6 illustrates a perspective view of aportion of cell lattice 240 of face plate 100, with inner skin 210,outer skin 120, and perimeter midsection area 232 removed for clarity.Cell lattice 240 comprises a plurality of cell junctions, such as celljunction 443, where two or more of walls 241 couple together. In thepresent example, the cell junctions provide an arcuate transitionbetween the walls of a cell. For example, walls 6412 and 6413 meet atcell junction 443, and the interface between them at cell junction 443is arcuate rather than pointed or sharp. In the present example, sucharcuate interface comprises a radius of approximately 0.05 inch(approximately 0.13 mm), but there can be other examples where thearcuate interface can comprise a radius of approximately 0.025 mm toapproximately 0.40 mm. Such arcuate features can be valuable, forexample, to avoid sharp edges or corners that could concentrate stressesthat could cause material fatigue and/or cracking within the celllattice.

Also in the present example, one or more of the cell junctions cancomprise respective junction channels, such as junction channel 4431extending into cell junction 443 from inner midsection end 245 to outermidsection end 246. Junction channel 4431 comprises a largest dimensionor diameter of approximately 0.015 inches (approximately 0.38 mm) in thepresent example, but there can be examples where similar junctionchannels can comprise a diameter and/or largest dimension ofapproximately 0.2 mm to approximately 0.66 mm.

In addition, cell lattice 240 also comprises one or more transversepassageways in the present example, such as transverse passageway 644between at least two adjacent cells of cells 242. Transverse passageway644 comprises a largest dimension or diameter of approximately 0.05inches (approximately 1.27 mm) in the present example, but there can beexamples where similar transverse passageways can comprise a diameterand/or largest dimension of approximately 0.5 mm to approximately 1.27mm.

The addition of features such as junction channel 4431 and transversepassageway 644 can permit additional reduction in weight withoutcompromising the strength or integrity of face plate 100. Also, thegeometry and/or shape of junction channel 4431 and/or passageway 644 canbe changed to be the same geometry and/or shape as cells 242 or anothergeometry and/or shape. Additionally, different ones of junction channel4431 and/or passageway 644 can have different geometries and/or shapes.

FIG. 7 illustrates a portion of cell lattice 740. In some examples, celllattice 740 can be similar to cell lattice 240 (FIGS. 1-4, 6), and maybe located between skins such as inner skin 210 and outer skin 120, asdescribed above with respect to face plate 100 in FIGS. 1-3. Celllattice 740 comprises walls 741 and cells 742, respectively similar towalls 241 and walls 242 (FIGS. 1-4, 6), but where walls 741 comprisevarying wall dimensions. As an example, the wall thickness dimension ofwall 7411 varies along its length, the wall thickness being thinnertowards the center of its length and thicker towards the ends of itslength. In the present example, such variation in wall thicknessdimension also affects the dimensions of cells 742, where the walls ofthe isogrid triangular cells comprise arcuate legs, and where thehexagonal shape defined by cells bounding a cell junction, such as celljunction 743, is now arcuate and/or circular. In other examples, thewall thickness dimensions could vary otherwise, such as by being thickertowards the center of their respective lengths, and by being thinnertowards the respective length ends thereof.

FIG. 8 illustrates a portion of cell lattice 840. In some examples, celllattice 840 can be similar to cell lattice 240 (FIGS. 1-4, 6) and/orcell lattice 740 (FIG. 7). Cell lattice 840 is located between skins 810and 820, which can be similar to inner skin 210 and/or outer skin 120,respectively, as described above with respect to face plate 100 (FIGS.1-4, 6). Cell lattice 840 comprises walls 841 and cells 842,respectively similar to walls 241 and cells 242 (FIGS. 1-4, 6), and/orto walls 741 and cells 742 (FIG. 7). Walls 841 comprise varying walldimensions in the present embodiment. As an example, the wall thicknessdimension of wall 8411 varies along its height, the wall thickness beingthinner towards the center of its height and thicker towards the ends ofits height. In the present example, such variation in wall thicknessdimension also affects the dimensions of cells 842, which can thuscomprise a greater volume and arcuate dimensions. In other examples, thewall thickness dimensions could vary otherwise, such as by being thickertowards the center of their respective heights, and by being thinnertowards the respective height ends thereof

Skipping ahead in the figures, FIG. 27 illustrates a portion or crosssection of cell lattice 1840 with varying wall dimensions. In someembodiments, cell lattice 1840 can be similar to cell lattice 240 (FIGS.1-4, 6), cell lattice 740 (FIG. 7), and/or cell lattice 840 (FIG. 8).Cell lattice 1840 is located between skins 1810 and 1820, which can besimilar to inner skin 210 and/or outer skin 120, respectively, asdescribed above with respect to face plate 100 (FIGS. 1-4, 6). Celllattice 1840 comprises walls 1841 and voids or cells 1842, respectivelysimilar to walls 241 and cells 242 (FIGS. 1-4, 6), to walls 741 andcells 742 (FIG. 7), and/or to walls 841 and cells 842 (FIG. 8).

Referring to FIG. 27, in the illustrated embodiment, cell walls 1841comprise a wall thickness 1851 that varies, similar to walls 841. Insome embodiments, the wall thickness 1851 is greater near the inner skin1810 and outer skin 1820 than near the central region of the lattice.For example, in the illustrated embodiment, the wall thickness dimensionof wall 1841 varies along its height, the wall thickness being thinnertowards the center of its height and thicker towards the ends of itsheight. Further, in the illustrated embodiment, the cell wall thickness1851varies defining an hourglass shape. The variation in wall thickness1851 also affects the dimensions of cells 1842, which can thus comprisea greater volume and arcuate dimensions. In other embodiments, the wallthickness 1851 can vary otherwise, such as by being thicker towards thecenter of their respective heights, and by being thinner towards therespective height ends thereof. Further, in other embodiments, the cellwalls 1841 can have any shape, such as circular, elliptical, square,rectangular, triangular, or any other polygon or shape with at least onecurved surface.

In many embodiments, the smallest or minimum wall thickness 1851 canrange from approximately 0.005 inches to approximately 0.2 inches. Insome embodiments, the smallest or minimum wall thickness 1851 can beless than or equal to approximately 0.20 inches, less than or equal toapproximately 0.15 inches, less than or equal to approximately 0.10inches, less than or equal to approximately 0.05 inches, or less than orequal to approximately 0.02 inches. For example, in the illustratedembodiment, the smallest or minimum wall thickness 1851 is approximately0.020 inches. In other embodiments, the smallest or minimum wallthickness 1851 can be approximately 0.025 inches, approximately 0.05inches, approximately 0.10 inches, approximately 0.15 inches, orapproximately 0.2 inches.

Further referring to FIG. 27, cells 1842 comprise a cell width 1852. Thecell width 1852 varies with distance from the inner skin 1810 and/orouter skin 1820. In the illustrated embodiment, cell width 1852 isgreatest near the center of cell 1851 and decreases near the inner skin1810 and outer skin 1820. In other embodiments, the cell width 1852 canvary in any capacity. For example, in other embodiments, the cell width1852 can be greatest near the inner skin 1810 and outer skin 1820, andcan decrease near the center of cell 1851.

In many embodiments, the largest or maximum cell width 1852 can rangefrom approximately 0.005 inches to approximately 0.2 inches. In someembodiments, the largest or maximum cell width 1852 can be less than orequal to approximately 0.20 inches, less than or equal to approximately0.15 inches, less than or equal to approximately 0.10 inches, less thanor equal to approximately 0.05 inches, or less than or equal toapproximately 0.025 inches. For example, in the illustrated embodiment,the largest or maximum cell width 1852 is approximately 0.045 inches. Inother embodiments, the largest or maximum cell width 1852 can beapproximately 0.025 inches, approximately 0.05 inches, approximately0.10 inches, approximately 0.15 inches, or approximately 0.2 inches.

In the illustrated embodiment, cells 1842 are coupled to one another, orare continuous throughout the cell lattice 1840. In other embodiments,cells 1842 can be discrete.

Further referring to FIG. 27, in the present embodiment, cell walls 1841are substantially hourglass shaped. Further, in the present embodiment,cell walls 1841 overlap or contact or intersect adjacent cell walls 1841at a single, first point near inner skin 1810 and at a single, secondpoint near outer skin 1820. Cell walls 1841 comprise cell wall axes 1844extending centrally within cell walls 1841 between inner skin 1810 andouter skin 1820. Cell walls 1841 are spaced apart from adjacent cellwalls 1841 by a center-to-center distance 1854 measured as the distancebetween adjacent cell wall axes 1844.

In many embodiments, the center-to-center distance 1854 between adjacentaxes 1844 can range from approximately 0.005 inches to approximately 0.2inches. In some embodiments, the center-to-center distance 1854 betweenadjacent axes 1844 can be less than or equal to approximately 0.20inches, less than or equal to approximately 0.15 inches, less than orequal to approximately 0.10 inches, less than or equal to approximately0.05 inches, or less than or equal to approximately 0.025 inches. Forexample, in the illustrated embodiment, the center-to-center distance1854 between adjacent axes 1844 is approximately 0.050 inches. In otherembodiments, the center-to-center distance 1854 between adjacent axes1844 can be approximately 0.025 inches, approximately 0.05 inches,approximately 0.10 inches, approximately 0.15 inches, or approximately0.2 inches.

Further referring to FIG. 27, cell walls 1841 extend at an angle 1850from cell wall axes 1844. In many embodiments, cell walls 1841 extend atan angle less than or equal to approximately 45 degrees from cell wallaxes 1844. In these or other embodiments, the face plate 100 having celllattice 1840 can be printed as described in method 50000 below withoutthe use of support structures within cells 1842. In other embodiments,cell walls 1841 can extend at any angle greater than 0 and less than 180degrees from cell wall axes 1844.

Referring to FIGS. 25 and 26, in the illustrated embodiment, a portionof the face plate 100 is formed with the cell lattice 1840. In these orother embodiments, the portion of the face plate 100 formed with thecall lattice 1840 can be subsequently coupled to the remainder of theface plate 100, as described in method 50000 below. In otherembodiments, the entire face plate 100 can be formed as a singlecomponent with the cell lattice comprising at least a portion of theface plate 100. For example, in other embodiments, the entire face plate100 can comprise the cell lattice 1840 and can be formed as a singlecomponent. For further example, in other embodiments, a portion (e.g.the center) of the face plate 100 can comprise the cell lattice 1840 andthe face plate 100 can be formed as a single component.

In the illustrated embodiment, the portion of the face plate 100 havingthe cell lattice 1840 is substantially circular. In other embodiments,the portion of the face plate 100 having the cell lattice 1840 cancomprise any other shape. For example, in other embodiments, the portionof the face plate 100 having the cell lattice 1840 can comprise anelliptical shape, as described in further detail in method 50000 below.For further example, in other embodiments, the portion of the face plate100 having the cell lattice 1840 can comprise a square, a triangle, anyother polygon, or any shape with at least one curved surface.

FIGS. 28A, 28B, and 28C illustrate a front, cross sectional view of aportion of a face plate 100 having cell lattice 1840 according tovarious embodiments. In the embodiment illustrated in FIG. 28A, cellwall axes 1844 are positioned radially from the center of the face plate100. In other embodiments, cell wall axes 1844 can have otherconfigurations. For example, cell wall axes 1844 can be configured in adiamond shaped pattern as illustrated in FIG. 28B, in a hexagonal shapedpattern as illustrated in FIG. 28C, or in any other configuration.Further, in the illustrated embodiments of FIGS. 28A-28C, cell wall axes1844 comprise the same spacing. In other embodiments, cell wall axes1844 can comprise different spacing.

In many embodiments, the cell lattice 1842 of face plate 100 reduces theweight of the face plate. In some embodiments, cell lattice 1842 of faceplate 100 reduces the weight of the face plate without sacrificingdurability. In some embodiments, cell lattice 1842 of face plate 100reduces the weight of the face plate, and the thickness of the faceplate is increased to maintain face plate durability. For example, insome embodiments, cell lattice 1842 can reduce the weight of the faceplate up to approximately 3 grams. In many embodiments, reduced weightof face plate 100 due to cell lattice 1842 allows additionaldiscretionary weight to be positioned elsewhere on the club head toachieve a desired head center of gravity or to increase club head momentof inertia to improve performance characteristics of the club head. Forexample, increased discretionary weight positioned on the perimeter ofthe club head can increase club head moment of inertia resulting inincreased club head forgiveness. In many embodiments, weight shiftedfrom the face plate to the perimeter of the club head can results in agreater increase in inertia than weight shifted from other portions ofthe club head (e.g. the crown). Further, in many embodiments, the celllattice 1842 of face plate 100 increase face plate flexibility,resulting in increased bending of the face plate on impact with a golfball, and therefore increased energy transfer to the golf ball andincreased ball speed and travel distance.

Backtracking through the figures, FIG. 11 illustrates a portion of celllattice 1140 with varying wall dimensions. In some examples, celllattice 1140 can be similar to cell lattice 240 (FIGS. 1-4, 6), celllattice 740 (FIG. 7), and/or cell lattice 840 (FIG. 8). Cell lattice1140 is located between skins 1110 and 1120, which can be similar toinner skin 210 and/or outer skin 120, respectively, as described abovewith respect to face plate 100 (FIGS. 1-4, 6). Cell lattice 1140comprises walls 1141 and cells 1142, respectively similar to walls 241and cells 242 (FIGS. 1-4, 6), to walls 741 and cells 742 (FIG. 7),and/or to walls 841 and cells 842 (FIG. 8). Walls 1141 also comprisevarying wall dimensions in the present embodiment, tapering in thicknessbetween skin 1110 and skin 1120. As an example, wall 11411 is thickertowards skin 1120, and decreases to a thinner thickness towards skin1110. In the same or other examples, skin 1120 is configured to comprisethe external surface of the faceplate, such that the thicker portion ofwalls 1141 face towards the impact surface of the faceplate. There maybe other embodiments, however, where the thinner portion of walls 1141can face towards the impact surface of the faceplate.

Backtracking through the figures, FIG. 9 illustrates a portion of celllattice 940. In some examples, cell lattice 940 can be similar to celllattice 240 (FIGS. 1-4, 6), cell lattice 740 (FIG. 7), cell lattice 840(FIG. 8), and/or cell lattice 1140 (FIG. 11). Cell lattice 940 islocated between skins 910 and 920, which can be similar to inner skin210 and/or outer skin 120, as described above with respect to face plate100 (FIGS. 1-4, 6). Cell lattice 940 comprises cells 942, which can besimilar to cells 242 (FIGS. 1-4, 6), to cells 742 (FIG. 7), to cells 842(FIG. 8), and/or to cells 1142 (FIG. 11). Cells 942 are offset from eachother in the present example. For instance, cell 9421 is offset fromcell 9422, which is offset from cell 9423. In addition, in the presentexample, midsection layers 931-933 define midsection 930 comprising celllattice 940. Midsection layers 931-933 can be similar to, and may bemerged together as described above, with respect to midsection layers330 of face plate 100 (FIG. 3). Each of midsection layers 931-933 cancomprise multiple layers before being merged together to form midsection930. In the present example, cell 9422 is at least partially capped ordefined by solid portions of midsection layers 931, 932, and 933 andcell 9421 is at least partially capped or defined by solid portions ofmidsection layers 931 and 932 and skin 920.

There can be other examples, however, that can comprise cell latticeswith other types of geometrical shapes, dimensions, or combinationsthereof. For instance skipping ahead to FIG. 12, cell lattice 1240 ispresented with walls 1241 defining hexagonal cells 1242. FIG. 13presents cell lattice 1340 with walls 1341 defining diamond or squarecells 1342. FIG. 14 presents cell lattice 1440 with walls 1441 defininground or circular cells 1442. Other shapes can also be implemented inthe same or other cell lattice examples, such as pentagonal cells,octagonal cells, triangular cells, and/or combinations thereof, amongothers. For instance, FIG. 15 presents cell lattice 1540 with walls 1541defining circular cells 1542 interspersed with triangular cells 1543.

There also can be examples where individual cells of a cell lattice cancomprise subcells therewithin. For example, cells 242 (FIGS. 1-4, 6) canbe considered in some examples as defining subcells of larger hexagonalcells of cell lattice 240. As another example, FIG. 16 presents celllattice 1640 with walls 1641 defining cells 1642, where cell subset 1650of cells 1642 comprise subcells 1652 defined by subwalls 1651 withinindividual cells of cell subset 1650. Cell subsets such as cell subset1650 may be located at specific locations to reinforce against stressesexpected thereat. In some examples, such cell subsets may be located ator by a target strike region of a faceplate, such as target strikeregion 150 of face plate 100 (FIG. 1). Other combinations of cells,subcells, shapes, and/or dimensions for a cell lattice may be formed bycombining different cells, subcells, shapes, and/or dimensions disclosedherein or similar thereto.

Although cell lattices 1240 (FIG. 12), 1340 (FIG. 13), 1440 (FIG. 14),1540 (FIG. 15), 1640 (FIG. 16), can differ in some aspects, they can beotherwise similar to one or more of cell lattices 240 (FIGS. 1-4, 6),cell lattice 740 (FIG. 7), cell lattice 840 (FIG. 8), and/or celllattice 1140 (FIG. 11).

In some examples, the height of the cells of a cell lattice may varyfrom cell to cell. As an example, FIG. 17 presents a cross-sectionalview of face plate 17100 with cell lattice 17240 similar to cell lattice240 (FIGS. 1-4, 6). Cell lattice 17240, however, comprises cells thatvary in height amongst each other. In the present example, the height ofcells 17242 is greater than the height of cells 17246, and the height ofcells 17246 is greater than the height of cells 17248. The cells of celllattice 17240 are positioned in the present example such as to decreasein height towards a center of target strike region 17150, where greaterstresses can be expected. In addition, the centermost portion of targetstrike region 17150 is devoid of any cell of cell lattice 17240 in thepresent example for further reinforcement. Other examples, however, maycomprise cell lattices with cells whose heights vary in a differentpattern.

FIG. 18 presents a front “x-ray” perspective view of a faceplate 18100of a golf club head. Faceplate 18100 comprises cell lattice 18240 withvariable cell dimensions. In the present example, cell lattice 18240comprises a grid of cells 18242 that decrease in size towards a centerof target strike region 18150. In the same or other examples, the wallsbetween cells 18242 of cell lattice 18240 can increase in thicknesstowards the center of target strike region 18150. In other examples, thesize of cells 18242, and/or the thickness of the walls therebetween, canincrease or decrease in size towards another region of faceplate 18100,such as towards the crown region, the sole region, the heel region,and/or the toe region.

In the same or other examples, the size of cells 18242 can decrease orincrease as a function of distance from the center of target strikeregion 18150. In other examples, however, the size and/or concentrationof cells 18242 can change relative to another feature of the faceplate,such as by increasing or decreasing from top edge to bottom edge or theface plate, and/or such as by increasing or decreasing from heel end totoe end of the face plate. In some embodiments, cells 18242 can decreasein size or dimension between approximately 1% to approximately 10% fromcell to cell as the distance to the center of target strike region 18150shortens. In the same or other embodiments, a distance between cells18242 can increase between approximately 1% to approximately 10% fromcell to cell as the distance to the center of target strike region 18150shortens. There can also be example where the change in size orconcentration of cells 18242, relative to the center of target strikeregion 18150, can change in a non-linear and/or a step function fashion.

Although cells 18242 of cell lattice 18240 are illustrated in FIG. 18 ascircular cells, cells 18242 can be representative of other shapes,sizes, or dimensions that can be used to implement the varying cell sizefeatures described above. For instance, the cells of cell lattice 18240could instead comprise other geometrical shapes such as triangles,hexagons, diamonds, octagons, pentagons, isogrids, and/or somecombination thereof in some implementations while still varying in sizeor concentration across at least a portion of face plate 18100.

FIG. 19 illustrates a front view of faceplate 19100 of a golf club head,where faceplate 19100 is subdivided into different cell lattice regions19500 with one or more cell lattices therewithin. In the presentexample, cell lattice regions 19500 comprise center lattice region 19510and periphery lattice region 19520, where center lattice region 19510 islocated at a center region of face plate 19100, bounded by peripherylattice region 19520 around its perimeter. Center lattice region 19510can be stiffer than periphery lattice region 19520, which is moreelastic in the present example, where the elasticity of cell latticeregions 19500 can be fine tuned by implementing appropriate cellpatterns, features, and/or dimensions to achieve a desired elasticmodulus range. In some examples, having center lattice region 19510stiffer relative to periphery lattice region 19520 can allow moreforgiveness for golf shots not hit at the target strike region of theface plate. In the same or other examples, a characteristic time (CT) ofa golf club can also be adjusted or controlled by adjusting theflexibility or elasticity of different portions of the face plate suchas cell lattice regions 19500. There can be other examples, however,where the center lattice region 19510 need not be stiffer than peripherylattice region 19520, and/or where center lattice region 19510 andperiphery lattice region 19520 can comprise a substantially similarstiffness or modulus of elasticity.

In some examples, center lattice region 19510 may be similar to orcorrespond to target strike region 150 of face plate 100 (FIG. 1), or toother target strike regions of other face plates described herein. Inthe present example, cell lattice regions 19500 can comprise or besimilar to one or more of the cell lattices described herein, but candiffer from each other with respect to at least one feature. As anexample, center lattice region 19510 can comprise a cell lattice similarto isogrid cell lattice 240 (FIGS. 1-4, 6), while periphery latticeregion 19520 can comprise a cell lattice similar to hexagonal celllattice 1240 (FIG. 12). As another example, center lattice region 19510can comprise a cell lattice similar to circular cell lattice 1440 (FIG.14), while periphery lattice region 19520 can comprise a cell latticesimilar to multi-shaped cell lattice 1540 (FIG. 15). As yet anotherexample, some cells of cell lattice regions 19500 can comprise subcellsand/or subwalls. For instance, cells of center lattice region 19510 cancomprise subcells and subwalls similar to cell subset 1650 (FIG. 16),while cells of periphery lattice region 19520 need not comprise subcellsor subwalls. In the same or other examples, cell lattice regions 19500can comprise cells of different heights. For instance, center latticeregion 19510 can comprise cells of a reduced height, such as the cellsof target strike region 17150 in FIG. 17, while periphery lattice region19520 can comprise cells of greater height than those of peripherylattice region 19520. In the same or other examples, center latticeregion 19510 may be partially or totally devoid of cells, whilesurrounded by the cells of periphery lattice region 19520.

FIG. 20 illustrates a front view of faceplate 20100 of a golf club head,where faceplate 20100 is subdivided into different cell lattice regions20500 with one or more cell lattices therewithin. In the presentexample, cell lattice regions 20500 comprise center lattice region 20510and periphery lattice regions 20520, where periphery lattice regions20520 comprise heel lattice region 20521 and toe lattice region 20522.Center lattice region 20510 is located at a center region of face plate20100, bounded at least partially by periphery lattice regions 20520.Cell lattice regions 20500 can comprise or be similar to one or more ofthe cell lattices described herein, but can differ from each other withrespect to at least one feature, such as in terms of stiffness,elasticity, and/or type of cell lattice comprised. As an example, centerlattice region 20510 extends towards the top and bottom ends offaceplate 20100, and can be otherwise similar to center lattice region19510 (FIG. 19), while periphery lattice regions 20520 can be similar toperiphery lattice region 19520 (FIG. 19). In the present examples, thecell lattices of periphery lattice regions 20520 can be similar to eachother, but there can be other examples where such cell lattices maydiffer from each other.

In the present example, center lattice region 20510 can be stiffer thanheel lattice region 20521 and toe lattice region 20522, while thestiffnesses of heel lattice region 20521 and of toe lattice region 20522can be similar to each other. There can also be examples, however, wherethe stiffnesses of heel lattice region 20521 can be greater than thestiffness of toe lattice region 20522, or vice-versa. The ability toestablish such different stiffness options for the different regions offaceplate 20100 can permit, for example, an optimization of ball speeddue to differences in club head speed across the faceplate as induced byclub head rotation about the golf shaft axis during swinging, theoffsetting of a bias in average impact location, and/or the fine-tuningof the shape or position of the club head's target strike region. Inaddition, cell lattice regions 20500 are separated from each other byone or more boundary channels 20600 in the present example. Boundarychannels 20600 are devoid of a cell lattice therewithin, but there alsocan be examples where boundary channels 20600 can comprise a celllattice similar to one or more of the cell lattices described herein. Inother examples, however, faceplate 20100 can be devoid of boundarychannels 20600, such that cell lattice regions 20500 contact or mergeinto each other.

FIG. 21 illustrates a front view of faceplate 21100 of a golf club head,where faceplate 21100 is subdivided into different cell lattice regions21500 with one or more cell lattices therewithin. In the presentexample, cell lattice regions 21500 comprise center lattice region 21510and periphery lattice regions 21520, where periphery lattice regions21520 comprise heel lattice region 21521, toe lattice region 21522, toplattice region 21523, and bottom lattice region 21524. Center latticeregion 21510 is located at a center region of face plate 21100, boundedat least partially by periphery lattice regions 21520. Cell latticeregions 21500 can comprise or be similar to one or more of the celllattices described herein, but can differ from each other with respectto at least one feature, such as in terms of stiffness, elasticity,and/or type of cell lattice comprised. As an example, center latticeregion 20510 can be similar to center lattice region 19510 (FIG. 19)and/or to center lattice region 20510 (FIG. 20). Periphery latticeregions 21520 can be similar to periphery lattice region 19520 (FIG. 19)and/or to periphery lattice regions 20520 (FIG. 20). In the presentexample, the cell lattices comprised by periphery lattice regions 21520differ from each other. For example, the cell lattices of top latticeregion 21523 and bottom lattice region 21524 differ from the celllattices of heel lattice region 21521 and toe lattice region 21522. Inthe same or other examples, the cell lattice of top lattice region 21523can be similar to the cell lattice of bottom lattice region 21524, whilethe cell lattice of toe lattice region 21522 can be similar to the celllattice of heel lattice region 21521. In other examples, however, thecell lattices of each of top lattice region 21523, bottom lattice region21524, toe lattice region 21522, and heel lattice region 21521 can allbe similar to each other.

In the present example, center lattice region 21510 can be stiffer thanperiphery lattice regions 21520. The stiffnesses of periphery latticeregions 21520 can be similar to each other or differ from each other,depending on the embodiment. For example, the stiffness of top latticeregion 21523 and of bottom lattice region 21524 may be stiffer than thestiffnesses of heel lattice region 21521 and of toe lattice region21522, or vice-versa. There can also be examples where each of peripherylattice regions 21520 can comprise a different stiffness. The ability toestablish such different stiffness options for the different regions offaceplate 21100 can permit further alternatives regarding benefitssimilar to those described above with respect to faceplate 20100. In thepresent example, cell lattice regions 21500 are separated from eachother by one or more boundary channels 21600, which can be similar toboundary channels 20600 (FIG. 20).

FIG. 22 illustrates a front view of faceplate 22100 of a golf club head,where faceplate 22100 is subdivided into different cell lattice regions22500 with one or more cell lattices therewithin. In the presentexample, cell lattice regions 22500 comprise center lattice region 22510and periphery lattice regions 22520, where periphery lattice regions22520 comprise top-heel lattice region 22521, top-toe lattice region22522, bottom-toe lattice region 22523, and bottom-heel lattice region22524. Center lattice region 22510 is located at a center region of faceplate 21100, bounded at least partially by periphery lattice regions22520. Cell lattice regions 22500 can comprise or be similar to one ormore of the cell lattices described herein, but can differ from eachother with respect to at least one feature, such as in terms ofstiffness, elasticity, and/or type of cell lattice comprised. In someexamples, center lattice region 22510 can be similar to center latticeregion 21510 (FIG. 21), while periphery lattice regions 22520 can besimilar to periphery lattice regions 21520, but shifted in terms oflocation across faceplate 22100. In one example, the stiffnesses and/orcell lattices of top-heel lattice region 22521 and of top-toe latticeregion 22522 may differ from the stiffnesses and/or cell lattices ofbottom-heel lattice region 22524 and of bottom-toe lattice region 22523.In another example, the stiffnesses and/or cell lattices of top-toelattice region 22522 and of bottom-toe lattice region 22523 may differfrom the stiffnesses and/or cell lattices of top-heel lattice region22521 and of bottom-heel lattice region 22524. There can also beembodiments where the stiffnesses and/or cell lattices of each ofperiphery lattice regions 22520 differ from each other. The ability toestablish such different stiffness options for the different regions offaceplate 22100 can permit further alternatives regarding benefitssimilar to those described above with respect to faceplate 20100 and/or21100. In the present example, cell lattice regions 22500 are separatedfrom each other by one or more boundary channels 22600, which can besimilar to boundary channels 20600 (FIG. 20).

Backtracking through the figures, FIG. 10 illustrates a flowchart for amethod 10000 for providing a face plate for a golf club head. In someembodiments, the face plate can be similar to face plate 100 (FIGS. 1-4,6), and or to a face plate comprising one or more cell lattices such asthose described with respect to FIGS. 7-9, 11, and/or 12-11).

Block 10100 of method 10000 comprises providing an inner skin of theface plate. Block 10200 of method 10000 comprises providing an outerskin of the face plate. In some examples, the inner skin of block 10100can be similar to inner skin 210, while the outer skin of block 10200can be similar to outer skin 120 (FIGS. 2-3). In the same or otherexamples, block 10100 may comprise providing first and second inner skinlayers of the inner skin, where such first and second inner skin layersmay be similar to inner skin layers 310 (FIG. 3). In the same or otherexamples, block 10200 may comprise providing first and second outer skinlayers of the outer skin, where such first and second outer skin layersmay be similar to outer skin layers 320 (FIG. 3).

Block 10300 of method 10000 comprises providing a midsection of the faceplate. In some examples, the midsection can be similar to midsection 230(FIGS. 1-4, 6) and/or midsection 930 (FIG. 9). In the same or otherexamples, block 10300 can comprise sub-block 10310 for providing firstand second midsection layers of the midsection of block 10300. There canbe examples where the first and second midsection layers can be similarto midsection layers 330 (FIG. 3). In the present example, the innerskin of block 10100, the outer skin of block 10200, and the midsectionof block 10300 are provided as separate distinct portions, althoughthere can be other embodiments where two of them may be provided alreadycombined together.

In some examples, block 10300 can also comprise sub-block 10320 forforming a cell lattice in the midsection, the cell lattice comprising aplurality of walls defining a plurality of cells. In some examples, thecell lattice can be similar to cell lattice 240 of midsection 230 (FIGS.2-6), to one or more of cell lattices 740 (FIG. 7), 840 (FIG. 8), 940(FIG. 9), 1140 (FIG. 11), 1240 (FIG. 12), 1340 (FIG. 13), 1440 (FIG.14), 1540 (FIG. 15), 1640 (FIG. 16), 17240 (FIG. 17), and/or 18240 (FIG.18), to one or more of the cell lattices comprised by the cell latticeregions of faceplate 19100 (FIG. 19), 20100 (FIG. 20), 21100 (FIG. 21),and/or 22100 (FIG. 22), and/or to other cell lattice variations similarto those described herein.

Sub-block 10320 may comprise sub-block 10321 for forming a first latticepattern of the cell lattice through the first midsection layer, and/orsub-block 10322 for forming a second lattice pattern of the cell latticethrough the second midsection layer. In some examples, the first latticepattern of sub-block 10321 can be similar to cell lattice pattern 341through midsection layer 331 (FIGS. 3-4). In the same or other examples,the second lattice pattern of sub-block 10322 can be similar to anotherlattice pattern of another midsection layer, such as lattice pattern 242of midsection layer 332 (FIG. 3). There can also be examples where thefirst and second lattice patterns of sub-blocks 10321-10322 cancorrespond to lattice patterns for the cell lattices of FIG. 7-9 or11-22, and/or to other cell lattice variations similar to thosedescribed herein.

Sub-block 10321 may comprise forming a first cutout through the firstmidsection layer, where the first cutout is configured to define a firstvolume portion of a first cell of the cell lattice. Similarly, sub-block10322 may comprise forming a second cutout through the second midsectionlayer, where the second cutout is configured to define a second volumeportion of the first cell of the cell lattice. As an example, the firstcutout may be similar to cutout 342 through midsection layer 331 (FIG.3), and the second cutout can be similar to cutout 343 throughmidsection layer 332 (FIG. 3) so that, when midsection layers 330 arecoupled together, such as through sub-block 10411 (below), the volumesdefined by cutouts 342 and 343 will combine to define at least part ofthe volume of a cell of cell lattice 240. There can be examples wheresub-block 10322 can comprise forming the second cutout to comprise adifferent dimension than the first cutout, such as a different radius, adifferent perimeter length, a different area, or a different volume.Accordingly, the first and second cutouts need not be equal to eachother, thereby adding flexibility to further define desired features forthe volume and/or shape of the cells of the cell lattice.

In some examples, forming the cell lattice in block 10320 can comprisealigning the second midsection layer over the first midsection layersuch that the first and second cutouts are centered about a first cellaxis of a cell of cell lattice 240. As an example, as described abovewith respect to FIGS. 3-4, midsection layers 300 comprise respectivealignment elements 351-354, and can be aligned with each other byaligning respective alignment members 351-354 throughout the stack ofmidsection layers 300. Accordingly, cutout 342 of layer 331 and cutout343 of layer 332 end up aligned relative to each other by being centeredabout cell axis 350, where cell axis 350 traverses through stackedcutouts of layers 330 to define a cell of cell lattice 240 in midsection230. In some examples, the alignment elements can comprise features suchas holes and/or indentions that can match each other for alignment bycorresponding shape and/or by location. With respect to the example ofFIGS. 3-4, alignment elements 351-354 are offset relative to each otherto permit alignment of adjacent ones of layers 300 only in a singleorientation.

There can also be examples where not all cutouts of stacked layers ofthe midsection need be aligned with each other centered about a cellaxis. In some embodiments, the cutouts and/or cells of the cell latticemay be offset from each other. For instance, forming the first latticepattern in block 10321 can comprise forming the first cutout through thefirst midsection layer to define a first volume portion of the firstcell, and forming the second lattice pattern block 10322 can compriseforming the second cutout through the second midsection layer to definea second volume portion of a second cell of the cell lattice. In thesame or other examples, the second cell can be at least partially cappedor defined by solid portions of the first midsection layer and/or theouter skin, and/or the first cell can be at least partially capped ordefined by solid portions of the second midsection layer and/or theinner skin. For instance, as shown in FIG. 9, midsection layers 931-933can be aligned and stacked relative to each other such that cells 9421,9422, and 9423 are offset from each other, such that cell 9421 is atleast partially capped or defined by solid portion 9321 of layer 932,and cell 9422 is at least partially capped or defined by solid portion9311 of layer 931. Although midsection 930 is shown in FIG. 9 as layers931-933 for simplicity, layers 931-933 may each represent a plurality ofmidsection layers stacked together in the same or other embodiments.

Block 10400 of method 10000 comprises coupling the midsection of block10300 between the inner skin of block 10100 and the outer skin of block10200. In some examples, the midsection may comprise an inner midsectionend coupled to the inner skin of block 10100, and an outer midsectionend coupled to the outer skin of block 10200, such that the midsectionis “sandwiched” therebetween. In the same or other examples, block 10400can comprise sub-block 10410 for merging the inner skin, the midsection,and the outer skin together into a single integral piece of materialwithout adhesives or fasteners. For instance, the inner skin, themidsection, and the outer skin may be merged together via a high-heatand high-pressure process as described above with respect to FIGS. 2-3,such as via a diffusion bonding process. There can be embodiments wheresub-block 10410 can be carried out such that the single integral pieceof material is seamless between the inner skin and the midsection, andbetween the midsection and the outer skin. In the same or otherexamples, sub-block 10410 can comprise sub-block 10411 for merging thefirst midsection layer and the second midsection layer togetherintegrally into the single piece of material. As an example, sub-block10411 can comprise merging midsection layers 330 together (FIG. 3) asdescribed above. In the same or other examples, sub-block 10410 can alsocomprise merging inner skin layers 310 (FIG. 3) together, and/or mergingouter skin layers 320 (FIG. 3) together into the single piece ofmaterial for the faceplate.

Such seamless and single-piece merging between the inner skin, the midsection and the outer skin, and/or between their respective layers, canoccur when the merging occurs at the molecular level. For example, theinner skin, the midsection, and the outer skin can all be provided tocomprise the same metallic material, where such material can be selectedto be suitable for merging the different portions of the faceplate atthe molecular level when exposed to a high heat and high-pressureprocess, such as through a diffusion bonding process. In some examples,the metallic material can comprise a metallic alloy, as described above,and the merging at the molecular level can take advantage of the crystalstructure of the metallic material to achieve integral bonding togenerate the single piece of material for the faceplate. As an example,the inner skin may be provided in block 10100 to comprise a firstcrystal structure of an alpha-type structure; the outer skin may beprovided in block 10200 to comprise a second crystal structure of thealpha-type structure; and the midsection may be provided in block 10300to comprise a midsection crystal structure of the alpha-type structure.Then, at block 10400, the first crystal structure of the inner skin, thesecond crystal structure of the outer skin, and the midsection crystalstructure of the midsection can be transformed into a beta-typestructure such that the midsection crystal structure is intermeshed withthe first crystal structure, and the midsection crystal structure isintermeshed with the second crystal structure. In some examples, thealpha-type structure can comprise a hexagonal crystal phase, and thebeta-type structure can comprise a body-centered cubic crystal phase.

Block 10500 of method 10000 can be optional, comprising coupling theface plate to a front end of the golf club head. In some examples, thegolf club head can be similar to golf club head 10 as illustrated inFIG. 1. The faceplate can be coupled by mating a faceplate edge, such asfaceplate edge 101 (FIGS. 1-2) to an opening at the front of the golfclub head. In some examples, such mating can be achieved via a weldingprocess and/or a brazing process.

In some examples, the cell lattice of the midsection, as formed insub-block 10320, can be located in a central midsection area of themidsection, such that a perimeter midsection area of the midsectionbounding the central midsection area can be devoid of the cell latticeand/or of its cells. As an example, the perimeter midsection area can besimilar to perimeter midsection area 232 of midsection 230 bounding thecentral area of midsection 230 comprising cell lattice 240 (FIGS. 1-4).In some embodiments, perimeter midsection area 230 can separate the celllattice 240 in the central midsection area away from faceplate edge 101by at least approximately 0.1 inches (2.54 mm).

In the same or other examples, coupling the face plate in block 10500can comprise coupling the front end of the golf club head to an innerskin perimeter area of the inner skin of block 10100, such as to innerskin perimeter area 212 (FIG. 2), or to an outer skin perimeter area ofthe outer skin of block 10200, such as to outer skin perimeter area 222(FIG. 2), or to both. For instance, the inner skin perimeter area and/orthe outer skin perimeter area can be aligned with the perimetermidsection area described above such as not to contact the cell latticeof the midsection central area. There can be other examples, however,where the cell lattice can extend throughout the midsection area of thefaceplate, such that the inner and outer skin perimeter areas would thuscontact the cell lattice.

The cell lattice formed in block 10320 can comprise one or more ofseveral characteristics. For example, the plurality of cells of the celllattice can be formed in a hexagonal pattern, such as seen in FIGS. 4and 6-7 with respect to cell lattice 240. In the same or other examples,the cell lattice can be formed in an isogrid pattern, as also seen withrespect to cell lattices 240 and 740. The cell lattice can comprise inthe same or other examples a plurality of cell junctions where two ormore of the plurality of walls couple together. For instance, the celljunctions can be similar to cell junction 443 (FIGS. 4, 6) and/or tocell junction 743 (FIG. 7). One or more of the cell junctions maycomprise a junction channel extending from the inner midsection end tothe outer midsection end of the midsection, such as junction channel4431 extended from inner midsection end 245 to outer midsection end 246through cell junction 443, as shown in FIG. 6.

Continuing with examples of the one or more several characteristics forthe cell lattice in block 10320, there can also be embodiments whereforming the cell lattice can comprise forming one or more walls of thecell lattice to comprise a varying dimension. As an example, the celllattice can comprise a wall, such as one of walls 741 having varyinglength thickness dimensions (FIG. 7), and/or such as one of walls 841and/or 1141 having varying depth thickness dimensions (FIGS. 8 and 11).In the same or other examples, forming the cell lattice can compriseforming the plurality of cells in a diminishing density pattern and/orin a diminishing size pattern. For instance, in the diminishing sizepattern, the plurality of cells can decrease in size or dimensiontowards a target strike region of the face plate, such as shown anddescribed with respect to FIGS. 17-18. In the diminishing densitypattern, the plurality of cells can decrease in density towards thetarget strike region of the face plate.

In the same or other examples, the cell lattice can comprise one or moretransverse passageways between adjacent cells of the cell lattice. As anexample, the cell lattice can comprise transverse passageways as shownin FIG. 6, where transverse passageway 644 traverses through wall 6411between adjacent cells of cells 242. In the same or other examples, theformation of the transverse passageways can be facilitated, for example,by the layered formation of midsection 230 (FIGS. 1-4, 6), where thefeatures of transverse passageways such as transverse passageway 644 canbe formed in block 10300 for each of midsection layers 330 prior tocarrying out block 10400.

There can also be examples where a single faceplate can comprise aplurality of cell lattice regions, such as described with respect toFIGS. 19-22. In some examples, the cell lattice regions of the pluralityof cell lattice regions can be similar to each other. In other examples,two or more of the cell lattice regions of the plurality of cell latticeregions can differ from each other with respect to at least one feature,such as in terms of stiffness, elasticity, and/or type of cell latticecomprised.

In some examples, one or more of the different blocks of method 10000can be combined into a single block or performed simultaneously, and/orthe sequence of such blocks can be changed. For example, the inner skinof block 10100 may be provided simultaneously with the midsection ofblock 10300, and/or the outer skin of block 10200 may be providedsimultaneously with the midsection of block 10300. As another example,the sequence of sub-blocks 10321 and 10322 can be changed.

In the same or other examples, some of the blocks of method 10000 can besubdivided into several sub-blocks. For example, block 10500 maycomprise a sub-block for fastening the face plate to the front end ofthe golf club head, and another sub-block for polishing the faceplateand/or the junction with the front end of the golf club head. There canalso be examples where method 10000 can comprise further or differentblocks. In addition, there may be examples where method 10000 cancomprise only part of the steps described above. For instance, block10500 can be optional in some examples. Other variations can beimplemented for method 10000 without departing from the scope of thepresent disclosure.

FIG. 23 illustrates a flowchart for a method 50000 of manufacturing aface plate for a golf club head. In some embodiments, the face plate canbe similar to face plate 100 (FIGS. 1-4, 6), and/or to a face platecomprising one or more cell lattices such as, for example, thosedescribed with respect to FIGS. 7-9, 11, 12-22, and/or 24-27).

Block 50100 of method 50000 comprises printing a face plate or a portionof a face plate for a golf club head, the face plate or portion thereofhaving a cell lattice with an inner skin 210, an outer skin 120, amidsection 230, and a plurality of apertures 160 (shown in FIG. 24).Each of the plurality of apertures 160 can extend from a cell within themidsection of the cell lattice through the inner skin, from a cellwithin the midsection of the cell lattice through the outer skin, orfrom a cell within the midsection of the cell lattice through the outerskin of the face plate.

Referring to FIG. 24, the plurality of apertures can be positioned onthe cell lattice to allow removal of excess powdered material of block50100. In some examples, at least one of the plurality of apertures 160is positioned near the center of the face plate or cell lattice regionand additional apertures 160 are positioned toward or near the perimeterof the face plate or cell lattice region. For example, in the embodimentillustrated in FIG. 25, the plurality of apertures 160 includes anaperture positioned near the center of the face plate and additionalapertures positioned around the perimeter of the cell lattice. In otherembodiments, the plurality of apertures 160 can include more than oneaperture positioned near the center of the face plate and additionalapertures positioned around the perimeter of the face plate or celllattice region. Further, in other embodiments, the plurality ofapertures 160 can include one or more apertures positioned near thecenter of the face plate and additional apertures positioned around theperimeter of the cell lattice forming a perimeter channel 168, asillustrated in FIG. 26. Referring to FIG. 26, in the illustratedembodiment, the perimeter channel has a width ranging from approximately0.03 to 0.05 inches. For example, the perimeter channel can have a widthof approximately 0.03 inches, approximately 0.035 inches, approximately0.04 inches, approximately 0.045 inches, or approximately 0.05 inches.In some embodiments, the perimeter channel can be positioned through theinner skin of the cell lattice. In other embodiments, the perimeterchannel can be positioned through the outer skin of the cell lattice.

In some examples, the plurality of apertures 160 can be positionedthrough or on a side of the face plate having the inner skin. In someexamples, the plurality of apertures 160 can be positioned through or ona side of the face plate having the outer skin. In some examples, someof the plurality of apertures 160 may be positioned through or on theside of the face plate having the inner skin and the remaining apertures160 can be positioned through or on the side of the face plate havingthe outer skin.

In many embodiments, the diameter of the plurality of apertures 160 canrange from approximately 0.005 inches to approximately 0.2 inches. Insome embodiments, the diameter of the plurality of apertures 160 canrange from approximately 0.025 inches to approximately 0.075 inches,from approximately 0.02 inches to approximately 0.10 inches, or fromapproximately 0.01 inches to approximately 0.15 inches. For example, inthe illustrated embodiment, the diameter of the plurality of apertures160 is approximately 0.05 inches. Further, in the illustratedembodiment, each of the plurality of apertures 160 has the samediameter. In other embodiments, each of the plurality of apertures canhave different diameters.

In many embodiments, each of the plurality of apertures 160 are spacedapart from the remaining apertures by a distance greater than or equalto two times the diameter of the plurality of apertures. In otherembodiments, each of the plurality of apertures can be spaced apart fromthe remaining apertures by a distance greater than or equal to three,four, five, or six times the diameter of the plurality of apertures.

In some examples, the face plate of block 50100 can be printed layer bylayer using direct metal laser sintering. In other examples, the faceplate can be printed using other processes such as, for example,selective laser sintering, 3D printing, stereolithography, laminatedobject manufacturing, fused deposition modeling, or electron beammelting. In some embodiments, the face plate having cell lattice (e.g.cell lattice 1840) cannot be formed using methods other than printing.For example, in many embodiments, the cells 1842 of cell lattice 1840comprise dimensions that are too small to be cast. For further example,in many embodiments, the continuous cells 1842 of cell lattice 1840prevent the usage of merging inner skin, midsection, and outer skinlayers together, as this process requires continuity in midsectionlayers.

In some examples, the face plate can be printed using a powderedmaterial. In some examples, the powdered material can be a powderedmetallic material. In some examples, the powdered metallic material ofblock 50100 can be a titanium alloy comprising at least approximately 8%aluminum (by volume). In the same or other examples, the metallic alloycan comprise a titanium 8-1-1 alloy having approximately 8% aluminum, 1%vanadium and 1% chromium. In the same or other examples, the powderedmetallic material of block 50100 can be a titanium alloy such as Ti-9Swhich contains 8% Al, 1% V, and 0.2% Si, with the remaining alloycomposition being titanium and possibly some trace elements. In someembodiments, Ti-9S contains 6.5%-8.5% Al, between 1%-2% V, a maximum of0.08% C, a maximum of 0.2% Si, a maximum of 0.3% Fe, a maximum of 0.2%O, a maximum of 0.05% N, trace amounts of Mo, and trace amounts of Sn,with the remaining alloy composition being titanium. Other materials maybe used depending on their strength, considering theirbrittleness/elasticity as a beta-type crystal structure. For example, atitanium 6-4 alloy having approximately 6% aluminum and 4% vanadium, maybe used in some embodiments, but can be from 5% to 12% less elastic thantitanium 8-1-1 and may thus require further reinforcement or thicknessfor face plate 100 to properly withstand golf impact stresses.

Block 50200 of method 50000 comprises removing the excess powderedmetallic material from the face plate printed in block 50100. In someexamples, removing the excess powdered material can be accomplishedusing compressed air directed toward the plurality of apertures 160, asdescribed below.

Block 50200 of method 50000 can comprise sub-block 50210 for applyingcompressed air to remove excess powdered material from the plurality ofapertures 160. The compressed air can be directed toward the pluralityof apertures 160 positioned on the perimeter of the face plate to createa void of excess powdered material around the perimeter of the faceplate. In some examples, the compressed air may range in pressure fromapproximately 30-60 PSI (pounds per square inch).

Block 50200 of method 50000 can also comprise sub-block 50220 forapplying force, pressure, or vibrations to the face plate to loosenexcess powdered material within the cell lattice. In some examples,force or pressure can be applied to the face plate using a rubbermallet. In other examples, force or pressure can be applied to the faceplate using any other method capable of loosening the excess powderedmaterial within the cell lattice. In some examples, vibrations can beapplied to the face plate in the form of ultrasonic vibrations. In otherexamples, any type of vibration capable of loosening excess powderedmaterial within the cell lattice can be applied to the face plate. Insome examples, vibrations can be applied to the face plate using atumbler or shaker. In other examples, any method capable of applyvibrations to the face plate to loosen excess powdered material can beused.

Block 50200 of method 50000 can also comprise sub-block 50230 forapplying compressed air to the at least one aperture 160 near the centerof the face plate. The compressed air directed toward the at least oneaperture 160 near the center of the face plate pushes the excessloosened powdered material from the cell lattice toward the perimeter ofthe face plate. In some examples, the compressed air may range inpressure from approximately 30-60 PSI.

Block 50200 of method 50000 can also comprise sub-block 50230 forapplying compressed air to the perimeter of the face plate to remove theexcess loosened powered material shifted from the center of the faceplate in the cell lattice to the perimeter of the face plate insub-block 50230. In some examples, the steps in sub-blocks 50220 and50230 can be repeated as necessary to remove any remaining excesspowdered material from the cell lattice of the face plate.

The plurality of apertures 160 of the face plate in method 50000function as a ventilation system to remove excess powdered material fromthe cell lattice of the face plate. The at least one aperture 160 nearthe center of the face plate aids in shifting the excess powderedmaterial from the center of the face plate in the cell lattice towardthe perimeter of the face plate in the cell lattice for simplifiedremoval compared to a face plate devoid of at least one aperture 160positioned near the center of the face plate.

Block 50300 of method 50000 can comprise filling in the plurality ofapertures 160 with a material similar or identical to the material ofthe face plate. In some examples, the plurality of apertures 160 can befilled in by welding. In other examples, the plurality of apertures 160can be filled in using other methods capable of filling the plurality ofapertures 160 resulting in a face plate having flush inner and outersurfaces.

Block 50400 of method 50000 can be optional, comprising coupling theface plate or portion thereof to a front end of the golf club head. Insome examples, the golf club head can be similar to golf club head 10 asillustrated in FIG. 1. In some examples (e.g. in examples where theentire face plate having the cell lattice is formed as a singlecomponent), the face plate can be coupled by mating a face plate edge,such as face plate edge 101 (FIGS. 1-2) to an opening at the front ofthe golf club head. In some examples, such mating can be achieved via awelding process and/or a brazing process. In examples where a portion ofthe face plate having the cell lattice is formed, the portion of theface plate can be coupled to a remainder of the face plate and/or thefront of the golf club head via a welding and/or brazing process.

In the same or other examples, some of the blocks of method 50000 can bedivided into several sub-blocks. There can also be examples where method50000 can comprise further or different blocks. For example, a stepincluding chemical dissolution can be performed after the step of block50200 to remove any additional excess powdered material within the celllattice. In some embodiments, chemical dissolution can be performedusing an acidic liquid at an elevated temperature (such as approximately37 degrees Celsius), the acid having a pH less than or equal toapproximately 4.0, such as, for example, acetic acid, benzoic acid,carbonic acid, citric acid, hydrochloric acid, nitric acid, sulfuricacid, or any other acid having a pH less than or equal to approximately4.0, or any other material capable of removing additional excesspowdered material within the cell lattice. In some embodiments, chemicaldissolution can be performed using isopropyl alcohol or any other liquidcapable of excess powdered material within the cell lattice.

For further example, method 50000 can further include an additional stepcomprising bending the face plate to incorporate bulge. In someexamples, bending the face plate can be performed after forming the faceplate with the cell lattice, but before coupling the face plate to thefront end of the club head. In other embodiments, the face plate can beformed with bulge such that a secondary bending operation is notrequired. In these or other embodiments, the geometry of the celllattice can be adjusted accordingly to allow the cell walls to extend atan angle less than or equal to approximately 45 degrees from a verticalaxis when the face plate or portion thereof is formed by printing,wherein the vertical axis is positioned perpendicular to a plane definedby a layer of printed material.

In the same or other examples, method 50000 can comprise only part ofthe steps described above. For instance, block 50400 can be optional insome examples. Further, there may be examples where steps of method50000 can be performed in different sequences. For instance, in someexamples, block 50400 can be performed before block 50300. Othervariations can be implemented for method 50000 without departing fromthe scope of the present disclosure.

Although the golf club face plates with internal cell lattices andrelated methods herein have been described with reference to specificembodiments, various changes may be made without departing from thespirit or scope of the present disclosure. For example, although golfclub head 10 is illustrated in FIG. 1 as a driver club head, thedisclosure herein is also applicable to other types of golf club heads,such as fairway woods, hybrids, and even club heads without internalcavities such as putters and irons. Additional examples of such changeshave been given in the foregoing description. Other permutations of thedifferent embodiments having one or more of the features of the variousfigures are likewise contemplated. Accordingly, the specification,claims, and drawings herein are intended to be illustrative of the scopeof the disclosure and is not intended to be limiting. It is intendedthat the scope of this application shall be limited only to the extentrequired by the appended claims.

The golf club face plates with internal cell lattices and relatedmethods discussed herein may be implemented in a variety of embodiments,and the foregoing discussion of certain of these embodiments does notnecessarily represent a complete description of all possibleembodiments. Rather, the detailed description of the drawings, and thedrawings themselves, disclose at least one preferred embodiment, and maydisclose alternative embodiments.

Clause 1: A golf club head comprising a face plate having an inner skin,an outer skin, a cell lattice with a plurality of walls having aplurality of axes extending centrally through the walls between theinner skin and the outer skin, wherein the walls extend from the axes atan angle less than or equal to approximately 45 degrees, and the wallsintersect adjacent walls at a single, first point near inner skin and ata single, second point near outer skin, a wall thickness that variesrelative to position from the inner skin and the outer skin, and aplurality of cells defined by the plurality of walls, the plurality ofcells positioned between the inner skin and the outer skin and having acell width that varies relative to position from the inner skin and theouter skin.

Clause 2: The golf club head of clause 1, wherein the wall thickness isgreater near the inner skin and the outer skin than near a centralregion of the cell lattice.

Clause 3: The golf club head of clause 1, wherein the minimum wallthickness ranges from 0.005 inches to 0.2 inches.

Clause 4: The golf club head of clause 1, wherein the maximum cell widthranges from 0.005 inches to 0.2 inches.

Clause 5: The golf club head of clause 1, wherein the thickness of thewalls varies defining a plurality of hourglass shapes.

Clause 6: The golf club head of clause 1, wherein a center-to-centerdistance between adjacent axes ranges from 0.005 inches to 0.2 inches.

Clause 7: The golf club head of clause 1, wherein the axes arepositioned radially from a center of the faceplate.

Clause 8: A cell lattice comprising an inner skin, an outer skin, aplurality of walls having a plurality of axes extending centrallythrough the walls between the inner skin and the outer skin, wherein thewalls extend from the axes at an angle less than or equal toapproximately 45 degrees, and a wall thickness that varies relative toposition from the inner skin and the outer skin, a plurality of cellsdefined by the plurality of walls, the plurality of cells positionedbetween the inner skin and the outer skin, and a plurality of aperturesfor removal of excess material in the cell lattice, the plurality ofapertures including at least a first aperture positioned near a centerof the cell lattice and a the remaining apertures positioned around theperimeter of the cell lattice.

Clause 9: The cell lattice of clause 8, wherein the wall thickness isgreater near the inner skin and the outer skin than near a centralregion of the cell lattice.

Clause 10: The cell lattice of clause 8, wherein the minimum wallthickness ranges from 0.005 inches to 0.2 inches.

Clause 11: The cell lattice of clause 8, wherein the maximum cell widthranges from 0.005 inches to 0.2 inches.

Clause 12: The cell lattice of clause 8, wherein the thickness of thewalls varies defining a plurality of hourglass shapes.

Clause 13: The cell lattice of clause 8, wherein a center-to-centerdistance between adjacent axes ranges from 0.005 inches to 0.2 inches.

Clause 14: The cell lattice of clause 8, wherein the axes are positionedradially from a center of the cell lattice.

Clause 15: The cell lattice of clause 8, wherein the plurality ofapertures is positioned through the inner skin of the cell lattice orthrough the outer skin of the cell lattice.

Clause 16: The cell lattice of clause 8, wherein the diameter of theapertures ranges from approximately 0.005 inches to 0.2 inches.

Clause 17: The cell lattice of clause 8, wherein each of the pluralityof apertures are spaced apart from the remaining apertures by a distancegreater than or equal to two times the diameter of the apertures.

Clause 18: A method of manufacturing a face plate of a golf club headcomprising: printing at least a portion of a face plate having a celllattice, the cell lattice including: an inner skin; an outer skin; aplurality of walls having a plurality of axes extending centrallythrough the walls between the inner skin and the outer skin, wherein thewalls extend from the axes at an angle less than or equal toapproximately 45 degrees; and a wall thickness that varies relative toposition from the inner skin and the outer skin; a plurality of cellsdefined by the plurality of walls, the plurality of cells positionedbetween the inner skin and the outer skin; and a plurality of aperturesfor removal of excess material in the cell lattice, the plurality ofapertures positioned through the inner skin or the outer skin, theplurality of apertures including at least a first aperture positionednear a center of the cell lattice and a the remaining aperturespositioned around the perimeter of the cell lattice; removing excesspowdered material from the cell lattice; and filling in the plurality ofapertures.

Clause 19: The method of manufacturing the face plate of a golf clubhead of clause 18, wherein removing excess powdered material includesapplying compressed air to the plurality of apertures positioned nearthe perimeter of the cell lattice, applying force or pressure to theface plate, and applying compressed air to the plurality of aperturespositioned near the center of the cell lattice.

Clause 20: The method of manufacturing the face plate of a golf clubhead of clause 18, wherein the diameter of the apertures ranges fromapproximately 0.005 inches to 0.2 inches, and each of the plurality ofapertures are spaced apart from the remaining apertures by a distancegreater than or equal to two times the diameter of the apertures.

Replacement of one or more claimed elements constitutes reconstructionand not repair. Additionally, benefits, other advantages, and solutionsto problems have been described with regard to specific embodiments. Thebenefits, advantages, solutions to problems, and any element or elementsthat may cause any benefit, advantage, or solution to occur or becomemore pronounced, however, are not to be construed as critical, required,or essential features or elements of any or all of the claims, unlesssuch benefits, advantages, solutions, or elements are expressly statedin such claims.

As the rules to golf may change from time to time (e.g., new regulationsmay be adopted or old rules may be eliminated or modified by golfstandard organizations and/or governing bodies such as the United StatesGolf Association (USGA), the Royal and Ancient Golf Club of St. Andrews(R&A), etc.), golf equipment related to the apparatus, methods, andarticles of manufacture described herein may be conforming ornon-conforming to the rules of golf at any particular time. Accordingly,golf equipment related to the apparatus, methods, and articles ofmanufacture described herein may be advertised, offered for sale, and/orsold as conforming or non-conforming golf equipment. The apparatus,methods, and articles of manufacture described herein are not limited inthis regard.

While the above examples may be described in connection with adriver-type golf club, the apparatus, methods, and articles ofmanufacture described herein may be applicable to other types of golfclub such as a fairway wood-type golf club, a hybrid-type golf club, aniron-type golf club, a wedge-type golf club, or a putter-type golf club.Alternatively, the apparatus, methods, and articles of manufacturedescribed herein may be applicable other type of sports equipment suchas a hockey stick, a tennis racket, a fishing pole, a ski pole, etc.

Moreover, embodiments and limitations disclosed herein are not dedicatedto the public under the doctrine of dedication if the embodiments and/orlimitations: (1) are not expressly claimed in the claims; and (2) are orare potentially equivalents of express elements and/or limitations inthe claims under the doctrine of equivalents.

1. A golf club head comprising: a face plate comprising: an inner skin;an outer skin; a cell lattice with a plurality of walls having: aplurality of axes extending centrally through the plurality of wallsbetween the inner skin and the outer skin, wherein the plurality ofwalls extend from the axes at an angle less than or equal toapproximately 45 degrees, wherein the plurality of walls intersectadjacent walls at a single, first point near the inner skin and at asingle, second point near the outer skin; a wall thickness that variesrelative to a position from the inner skin and the outer skin; aplurality of cells defined by the plurality of walls, the plurality ofcells positioned between the inner skin and the outer skin; and aplurality of apertures for removal of excess material in the celllattice, the plurality of apertures including at least one aperturepositioned near a center of the cell lattice and additional aperturespositioned around a perimeter of the cell lattice; wherein theadditional apertures form a channel positioned through the inner skin orthrough the outer skin; wherein the cell lattice further comprises aplurality of midsection layers comprising a first midsection layer and asecond midsection layer, each comprising a plurality of cells; whereinthe cell lattice in the midsection comprises a first lattice pattern ofthe cell lattice through the first midsection layer; and a secondlattice pattern of the cell lattice through the second midsection layer;wherein the first midsection layer is closer to the inner skin than thesecond midsection layer; wherein the second midsection layer is closerto the outer skin than the first midsection layer; and wherein the firstand second midsection layers are offset relative to each other such thatthe plurality of cells of the second midsection layer are at leastpartially capped by a solid portion of the plurality of cells of thefirst midsection layer; and wherein the plurality of cells of the firstmidsection layer are at least partially capped by a solid portion of theplurality of cells of the second midsection layer.
 2. The golf club headof claim 1, wherein the wall thickness is greater near the inner skinand the outer skin than near a central region of the cell lattice andwherein the plurality of apertures are filled with a material identicalto a material of the face plate.
 3. The golf club head of claim 1,wherein the minimum wall thickness ranges from 0.005 inches to 0.2inches.
 4. The golf club head of claim 1, wherein a width of the channelranges from 0.03 inches to 0.05 inches.
 5. The golf club head of claim1, wherein varying wall thickness defines a plurality of hourglassshapes.
 6. The golf club head of claim 1, wherein a center-to-centerdistance between adjacent axes ranges from 0.005 inches to 0.2 inches.7. The golf club head of claim 1, wherein the axes are positionedradially from a center of the faceplate.
 8. The golf club head of claim1, wherein the perimeter of the cell lattice is selected from the groupconsisting of hexagonal, diamond, square, circular, circularinterspersed with triangles, and cell subsets with walls.
 9. The golfclub head of claim 1, wherein the cell lattice is located at a region ofthe face plate, and the region is selected from the group consisting ofa center, heel, and toe lattice region, a center, heel, toe, top, andbottom lattice region, and a center, top-heel, top-toe, bottom-heel, andbottom-toe lattice region.
 10. The golf club head of claim 1, whereinthe plurality of apertures are filled with a metallic alloy.
 11. A golfclub head comprising: a face plate comprising: an inner skin; an outerskin; a cell lattice with a plurality of walls having: a plurality ofaxes extending centrally through the plurality of walls between theinner skin and the outer skin, wherein the plurality of walls extendfrom the axes at an angle less than or equal to approximately 45degrees, wherein the plurality of walls intersect adjacent walls at asingle, first point near the inner skin and at a single, second pointnear the outer skin; a wall thickness that varies relative to positionfrom the inner skin and the outer skin; a plurality of cells defined bythe plurality of walls, the plurality of cells positioned between theinner skin and the outer skin and having a cell width that variesrelative to a position from the inner skin and the outer skin; and aplurality of apertures for removal of excess material in the celllattice, the plurality of apertures including at least one aperturepositioned near a center of the cell lattice and additional aperturespositioned around a perimeter of the cell lattice; wherein theadditional apertures form a channel positioned through the inner skin orthrough the outer skin; wherein the cell lattice further comprises aplurality of midsection layers comprising a first midsection layer and asecond midsection layer, each comprising a plurality of cells; whereinthe cell lattice in the midsection comprises a first lattice pattern ofthe cell lattice through the first midsection layer and a second latticepattern of the cell lattice through the second midsection layer; whereinthe first midsection layer is closer to the inner skin than the secondmidsection layer; wherein the second midsection layer is closer to theouter skin than the first midsection layer; and wherein the first andsecond midsection layers are offset relative to each other such that theplurality of cells of the second midsection layer are at least partiallycapped by a solid portion of the plurality of cells of the firstmidsection layer; and wherein the plurality of cells of the firstmidsection layer are at least partially capped by a solid portion of theplurality of cells of the second midsection layer.
 12. The golf clubhead of claim 11, wherein the wall thickness of the cell lattice isgreater near the inner skin and the outer skin than near a centralregion of the cell lattice.
 13. The golf club head of claim 11, whereina minimum wall thickness of the cell lattice ranges from 0.005 inches to0.2 inches.
 14. The golf club head of claim 11, wherein a width of thechannel ranges from 0.03 inches to 0.05 inches.
 15. The golf club headof claim 11, wherein the thickness of the plurality of walls variesdefining a plurality of hourglass shapes.
 16. The golf club head ofclaim 11, wherein a center-to-center distance between adjacent axes ofthe cell lattice ranges from 0.005 inches to 0.2 inches.
 17. The golfclub head of claim 11, wherein the plurality of axes of the cell latticeare positioned radially from a center of a faceplate.
 18. The golf clubhead of claim 11, wherein a diameter of the plurality of aperturesranges from approximately 0.005 inches to 0.2 inches.
 19. The golf clubhead of claim 11, wherein individual cells of the cell lattice furthercomprise subcells; wherein the subcells are defined by subwalls withinindividual cells; wherein the subcells are located at or proximate to afaceplate target strike region.
 20. The golf club head of claim 11,wherein individual cells of the cell lattice increase in size in a rangeof 1% to 10% comparing cells proximate a faceplate toe region or heelregion to cells proximate a faceplate target strike region.